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Multifunctional Dust Deputy Cart

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Project by EarlS posted 02-27-2020 03:21 PM 872 views 2 times favorited 13 comments Add to Favorites Watch

After building the big 5” SDD system for the big pieces of equipment in the shop, I decided that I needed a small cyclone for the shop vac so I wasn’t constantly emptying out the shop vac and cleaning the filter. There are numerous versions of Dust Deputy carts on LJ, and elsewhere online. I looked at the various options and pondered what I really wanted from my version. I quickly settled on a cart that had a large work surface and housed all of the dust collection underneath. I also decided to include a drawer since there was room for one.

The cart is 42” long, 25” wide, and 35” tall. That makes the work top too high for comfortably using the Leigh jigs (see picture 1). 32” would have been a better height.

The top is 6/4 maple (46×31) with breadboard ends and it is elevated above the cabinet by 1” which allows for clamps to slide a bit further under the table when clamping things together. That made the final height nearly 38”.

I purchased the Oneida Dust Deputy at the local Menards, along with a new Shop Vac, 3- 4×4 sheet of 3/4” baltic birch plywood, and 3” locking casters. The cabinet was built using rabbets for the corners and dividers, then gluing and screwing everything together. It was primed and painted grey.

The cyclone was anchored on a shelf with a hole cut through the board for the cyclone chip outlet. The chips fall into a plastic tote that sits in a sealed compartment. The access door is sealed with weather stripping and lock down toggles.

The cyclone inlet (on the side) fit well with the 2-1/2” shop vac hose and was secured using some hose clamps. Initially, the outlet also used shop vac hose, but I quickly realized that the vacuum was collapsing the hose between the top of the cyclone and the inlet to the shop vac. I wound up taking the cyclone and some shop vac hose to Menards and camped out in the plumbing section while I pieced together the necessary PVC fittings that would fit the odd sizes of both the cyclone and the shop vac hose. A combination of 1-1/2” and 2” fittings and pipe, combined with a healthy does of silicone and some more hose clamps, provided the final solution.

Initially, I was going to install an autoswitch 110V outlet so I wouldn’t have to turn the shop vac on every time I used a tool, but decided to wait and see if it was really neccessay. In the meantime, there is an outlet mounted on the end of the cabinet for the shop vac and whatever tool I’m using. I also included a hanger for the hose, though it doesn’t get used much since the 2-1/2” hose is bulky. I might move it to the back.

I had to add several vent holes in the back of the section that houses the shop vac to allow the air coming out of the vacuum to vent. I may need to add more since the compartment also gets quite warm from the shop vac if I’m using it for a long time.

I’m still considering options for storing the shop vac accessory pieces; wand sections and end attachments. I’m leaning toward making a holder that mounts to the side of the cabinet with holes for the various pieces.

After using this set up for the past few months, I came to the realization that I’m still cleaning the shop vac filter as often as before since much of the fine dust from sanding will not be removed by the cyclone. While the collection tote doesn’t need to be emptied as often, it is more of a chore than if I were emptying the shop vac. In the end, I’m not sure the cyclone system is any better than just using the shop vac.

-- Earl "I'm a pessamist - generally that increases the chance that things will turn out better than expected"





13 comments so far

View GR8HUNTER's profile

GR8HUNTER

7197 posts in 1394 days


#1 posted 02-27-2020 03:51 PM

something must be very wrong here with MINE MY FILTER STAYS VERY CLEAN no problems as of yet :<))

-- Tony---- Reinholds,Pa.------ REMEMBER TO ALWAYS HAVE FUN

View EarlS's profile

EarlS

3602 posts in 3030 days


#2 posted 02-27-2020 04:03 PM

Do you do a lot of sanding? I sanded 30 cherry drawer fronts for the closet cabinets using a belt sander hooked up to the DD and the filter in the Shop Vac was full. There was a fair amount of the dust in the cyclone dust bin too, but nothing like 90%. Now I’m wondering if I need a deeper dust bin under the cyclone for disengagement? You have a 5 gal bucket which is taller than the tote I’m using.

-- Earl "I'm a pessamist - generally that increases the chance that things will turn out better than expected"

View HokieKen's profile

HokieKen

12884 posts in 1820 days


#3 posted 02-27-2020 04:08 PM

That cart really sucks Earl.

;-)

-- Kenny, SW VA, Go Hokies!!!

View Bill_Steele's profile

Bill_Steele

678 posts in 2413 days


#4 posted 02-27-2020 04:20 PM

Love the cart Earl. That Dust Deputy is a wonderful thing.


That cart really sucks Earl.

;-)

- HokieKen

I almost laughed out loud… the sarcasm is palpable.

View GR8HUNTER's profile

GR8HUNTER

7197 posts in 1394 days


#5 posted 02-27-2020 04:28 PM

RIGHT NOW it is just hooked up to my sanders only belt/disc and spindle :<))

-- Tony---- Reinholds,Pa.------ REMEMBER TO ALWAYS HAVE FUN

View socrbent's profile

socrbent

951 posts in 2951 days


#6 posted 02-27-2020 05:10 PM

The filter in my shop vac stays amazingly clean. I agree with Tony that there is a problem with your configuration. Possibly air infiltration to the chip/dust collection bin under the cyclone. But you do have a nice looking and useful cabinet.

-- socrbent Ohio

View splintergroup's profile

splintergroup

3451 posts in 1904 days


#7 posted 02-27-2020 05:30 PM

Earl, are those standard schedule 40 PVC fittings you used? I’m still waiting to get around to consolidating my DD “hardware” into a functional setup. I love the portable bench top idea you have here 8^)

I do lots of sanding with my setup and never get any dust into the shop vac. I’m wondering if your square receptacle may be hindering the the DD vortex. I have mine attached to the lid of a standard 5-gallon plastic drywall mud bucket, it gets emptied every few months.

View oldrivers's profile

oldrivers

2052 posts in 2248 days


#8 posted 02-27-2020 06:27 PM

Looks Good hope you solve the dust problem?

-- Soli Deo gloria!

View clagwell's profile

clagwell

147 posts in 474 days


#9 posted 02-27-2020 06:28 PM


Now I m wondering if I need a deeper dust bin under the cyclone for disengagement? You have a 5 gal bucket which is taller than the tote I m using.

- EarlS

I think you’re onto something there. Does the dust in the bin show evidence of the vortex reaching into the dust pile, i.e., swirl marks? Cyclones sometimes use a vortex breaker below the outlet to stop that, especially on cyclones with a large outlet to barrel diameter ratio. A simple small vertical baffle spanning the underside of the outlet is what I would try first.

-- Dave, Tippecanoe County, IN

View therealSteveN's profile

therealSteveN

5211 posts in 1256 days


#10 posted 02-27-2020 07:37 PM



Do you do a lot of sanding? I sanded 30 cherry drawer fronts for the closet cabinets using a belt sander hooked up to the DD and the filter in the Shop Vac was full. There was a fair amount of the dust in the cyclone dust bin too, but nothing like 90%. Now I m wondering if I need a deeper dust bin under the cyclone for disengagement? You have a 5 gal bucket which is taller than the tote I m using.

- EarlS

Earl, didja get 11% off on the DD? I’d have to look, but I don’t think our Menards has them here. I love the all in inside of one cabinet idea, just wonder if you will need to stack them to make it a go. That would kinda make for a tall cabinet though.

I have one of the Rockler trash can looking Blue cyclones, so maybe mine works different? I am attached to the hose coming right out of the Rockler deal, and it is attached to my Fein vac. I know with mine if the vac and the can are both on the ground I get really ok collection in the Rockler can. If the Fein is above the Rockler can, almost all really fine dust like you get from sanding, or tooling MDF, goes to the Fein vac/filter. Now if I raise up the Rockler can similar to how Tony shows his, I get nothing at all in the Fein, the filter on the Fein. This is true even with drywall dust from sanding a wall after the mud dries. Reallllly reallllly fine dust there, and if the Rockler is higher, it works 100%.

Might give you something to try. If you pull out the DD, and put it above the vac, and the vac comes up empty, you may have to mount the DD on the back side of the worktable, above the height of the shop vac.

If you look at pics of a DD, and a vac, in most the DD line going out to the dust (I presume this is how they work) is higher than the top of the vac.

https://www.google.com/search?q=Shop+vac,+with+a+dust+deputy&client=firefox-b-1-d&source=lnms&tbm=isch&sa=X&ved=2ahUKEwiJkcaTvfLnAhXH854KHU0OA3EQ_AUoAnoECAsQBA&biw=1360&bih=632

Best of luck.

-- Think safe, be safe

View fivecodys's profile

fivecodys

1603 posts in 2318 days


#11 posted 02-27-2020 09:05 PM

This thread is too funny.
It took me a minute but I got it!

-- A bad day woodworking is still better than a good day working.

View Green_Hornut's profile

Green_Hornut

174 posts in 3302 days


#12 posted 02-27-2020 11:09 PM

I have to agree with Tony about the filter. I made a DD set up last winter. It’s posted in the reviews. I have emptied the bucket 5 times so far and here is a picture of the filter after those 5 buckets. You would think I just attached it. I bought a 5 pack of filters for my Fein and I’m beginning to think that is going to be a lifetime supply.

-- Mother Nature always bats last.

View EarlS's profile

EarlS

3602 posts in 3030 days


#13 posted 02-28-2020 02:24 AM

Steve – 11% off of $45 as a mail in rebate. I found it on Menards website for my local store and still needed some help finding it.

Dave – there is a vortex when the level in the dust bin is more than 1/2 full. I just emptied and cleaned everything out, then hooked up the sander. I’ll look at things in the morning and see what the filter looks like.

The dust bin is completely air tight. The weather strip does a great job.

The fittings are standard SCH40 PVC from the plumbing section.

I’m going to give the vortex breaker a try before I initiate wholesale changes to the cyclone dust bin. I seem to recall seeing a simple version that was little more than a couple pieces of cardboard in the shape of an “X” wedged into the bottom flange.

-- Earl "I'm a pessamist - generally that increases the chance that things will turn out better than expected"

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